GUIDE SPECIFICATION

Classic Vertical Tubeless Boilers (ICS)

Models: ICS – 4, 6, 8.5, 9.5, 10, 15, 20, 25, 30, 50, 60

SECTION 1: General
1.1: SCOPE
A. The work to be performed includes all new equipment, labor and materials required to furnish and
install Vertical Tubeless Fulton ICS (Classic) Boilers as described in this product guide specification.

1.2: REFERENCES
A. ASME
B. CSD1, Controls and Safety Devices
C. CSA/CUL
D. GE GAP
E. NFPA
F. NEC, National Electric Code
G. UL-795, -508A

1.3: SUBMITTALS

A. Product Data: Submit manufacturer’s technical product data, including rated capacities of selected
model, weights (shipping, installed and operating), installation and start-up instructions, and furnished
accessory information.
B. Shop Drawings: Submit manufacturer’s end assembly drawings indicating dimensions, connection
locations, and clearance requirements.
C. Wiring Diagrams: Submit applicable manufacturer’s electrical requirements for the boiler including
ladder type wiring diagrams for interlock and control wiring. Clearly differentiate between portions of
wiring that are factory installed and portions to be field installed.

1.4: QUALITY ASSURANCE

A. Manufacturer’s Qualifications: Firms regularly engaged in the manufacture of vertical tubeless boilers
and pressure vessels, whose products have been in satisfactory use in service for not less than sixty
(60) years. The manufacturer must be a privately owned, American company. The boiler must be
manufactured in the USA and be able to participate in projects that require a level of USA content of
boiler materials. The specifying engineer, contractor and end customer must have the option to visit
the factory during the manufacture of the boilers and be able to witness manufacturing, test fire, and
other relevant procedures.
B. The boiler package shall be certified to UL 795.

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 C. The boiler will be rated for a maximum allowable working pressure of 150 PSIG for ASME Section I
(100psi for the ICS-9.5), or higher pressures upon request. Refer to job schedule for additional
clarification.
D. The flame safeguard to control the supply of fuel and air to the boiler for combustion shall be either
the Honeywell 7895 series for on/off operation, the Honeywell 7800 series for modulated linkage-type
operation.
E. The entire boiler system and its installation shall conform to the manufacturer’s instructions,
applicable codes and associated National Board requirements.
F. The equipment shall be in strict compliance with the requirements of this specification and shall be the
manufacturer’s standard commercial product unless specified otherwise. Additional equipment
features, details, accessories, etc. which are not specifically identified but which are a part of the
manufacturer’s standard commercial product, shall be included in the equipment being furnished.
G. The equipment shall be of the type, design, and size that the manufacturer currently offers for sale and
appears in the manufacturer’s current catalog.
H. The equipment shall fit within the allocated space, leaving ample allowance for maintenance and
inspection.
I. The equipment shall be new and fabricated from new materials. The equipment shall be free from
defects in materials and workmanship.
J. All units of the same classification shall be identical to the extent necessary to ensure
interchangeability of parts, assemblies, accessories, and spare parts wherever possible.
K. In order to provide unit responsibility for the specified capacities, efficiencies, and performance, the
boiler manufacturer shall certify in writing that the equipment being submitted shall perform as
specified.
L. Boilers must be fully factory test fired prior to shipment. Test firing shall include filling with water,
adjusting operating and safety control settings, and setting combustion points. Manufacturer shall
supply copies of the test fire report, including fuel air settings and combustion test results. Factory
representatives, specifying engineers, installing contractors and/or end users/customers shall all be
welcome to witness the boiler being built and/or test fired at the manufacturer’s factory.
M. Boiler inspection shall include a hydrostatic test in the presence of an inspector having a National
Board Commission. He shall certify a Data Report which shall be delivered with the boiler as evidence
of ASME code compliance. In addition to the ASME symbol, the boiler shall bear a National Board
Registration Number.

1.5: WARRANTY

A. Boiler
A.1 Five (5) Year (60 Months) Material and Workmanship Warranty:
i. The pressure vessel is covered against defective material or workmanship for a period of five
(5) years from the date of shipment from the factory. Fulton will repair or replace F.O.B.
factory any part of the equipment, as defined above, provided this equipment has been
installed, operated and maintained by the buyer in accordance with approved practices and

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 recommendations made by Fulton. The commissioning agency must also successfully
complete and return the equipment Installation and Operation Checklists to Fulton's Quality
Assurance department. This warranty covers any failure caused by defective material or
workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is
imperative that the boiler water management and chemistry be maintained as outlined in
the Installation and Operation Manual.

A.2 Parts Warranty:

i. Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that
is found to be defective in workmanship or material within one (1) year of shipment from the
factory provided this equipment has been installed, operated and maintained by the buyer in
accordance with approved practices and recommendations made by both Fulton and the
component manufacturers and the commissioning agency has successfully completed and
returned the equipment Installation and Operation Checklists to Fulton's Quality Assurance
department.

A.3 General:
i. Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty
does not include freight, handling or labor charges of any kind. These warranties are
contingent upon the proper sizing, installation, operation and maintenance of the boiler and
peripheral components and equipment. Warranties valid only if installed, operated, and
maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or
other representative of Fulton other than the Quality Manager or an officer of the company
has warranty authority. Fulton will not pay any charges unless they were pre-approved, in
writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other
warranties, expressed or implied, including but not limited to the implied warranties of
merchantability and fitness for a particular purpose. Fulton shall in no event be liable for any
consequential or incidental damages arising in any way, including but not limited to any loss
of profits or business, even if the Fulton Companies has been advised of the possibility of
such damages. Fulton's liability shall never exceed the amount paid for the original
equipment found to be defective. To activate the warranty for this product, the appropriate
commissioning sheets must be completed and returned to the Fulton Quality Assurance
department for review and approval.

B. Premier Steam Engineered System

B.1 Ten (10) year (120 months) Material and Workmanship Warranty:
i. The pressure vessel is covered against defective material or workmanship for a period of ten
(10) years from the date of shipment from the factory. Fulton will repair or replace F.O.B.
factory any part of the equipment, as defined above, provided this equipment has been
installed, operated and maintained by the buyer in accordance with approved practices and
recommendations made by Fulton. The commissioning agency must also successfully
complete and return the equipment Installation and Operation Checklists to Fulton's Quality
Assurance department. This warranty covers any failure caused defective material or
workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is
imperative that the boiler water management and chemistry be maintained as outlined in

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 the Installation and Operation Manual. There is a $1,000 labor allowance for any failed
pressure vessel that is covered under the above warranty.

B.2 Parts Warranty:

i. Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that
is found to be defective in workmanship or material within one (1) year of shipment from the
factory provided this equipment has been installed, operated and maintained by the buyer in
accordance with approved practices and recommendations made by both Fulton and the
component manufacturers and the commissioning agency has successfully completed and
returned the equipment Installation and Operation Checklists to Fulton's Quality Assurance
department.

B.3 General:
i. The extended warranty is valid only for boilers that are purchased as part of a Premier Steam
Engineered System. Generally, this system MUST include ALL of the following equipment in
order for the warranty to apply. Any deviation or additional equipment specified by Fulton
Engineering must be used and maintained per the Installation and Operation Manual as well:
Fulton Boiler with model number as listed above; feedwater or DA system with preheat kit;
Fulton blowdown tank; Water softener; Chemical feed system; Automatic surface or timer
based bottom blowdown, which must operate to maintain a TDS level as specified in the
Installation and Operation Manual. Fulton shall be notified in writing as soon as any defect
becomes apparent. This warranty does not include freight, handling or labor charges of any
kind except as noted above. These warranties are contingent upon the proper sizing,
installation, operation and maintenance of the boiler and peripheral components and
equipment. Warranties valid only if installed, operated, and maintained as outlined in the
Fulton Installation and Operation Manual. No Sales Manager or other representative of
Fulton other than the Quality Manager or an officer of the company has warranty authority.
Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton
Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or
implied, including but not limited to the implied warranties of merchantability and fitness for
a particular purpose. Fulton shall in no event be liable for any consequential or incidental
damages arising in any way, including but not limited to any loss of profits or business, even
if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability
shall never exceed the amount paid for the original equipment found to be defective. This
warranty applies only in the U.S.A. and Canada. To activate the warranty for this product, the
appropriate commissioning sheets must be completed and returned to the Fulton Quality
Assurance department for review and approval.

SECTION 2: Products

2.1: ACCEPTABLE MANUFACTURERS

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 A. This specification is based on the ICS Series boilers as manufactured by Fulton Boiler Works, Inc.
Equivalent units and manufacturers must meet all performance criteria for all fuel options, and will be
considered upon prior approval.
B. Basis of Design: Fulton Boiler Works, Inc. Models:

B.1 ICS-4 – 138 lb/hr (134,000 BTU/hr)

B.2 ICS-6 – 207 lb/hr (201,000 BTU/hr)
B.3 ICS-8.5 – 293 lb/hr (208,000 BTU/hr)
B.4 ICS-9.5 – 328 lb/hr (319,000 BTU/hr)
B.5 ICS-10 – 345 lb/hr (335,000 BTU/hr)
B.6 ICS-15 - 518 lb/hr (503,000 BTU/hr)
B.7 ICS-20 – 690 lb/hr (670,000 BTU/hr)
B.8 ICS-25 – 863 lb/hr (837,000 BTU/hr)
B.9 ICS-30 – 1,035 lb/hr (1,005,000 BTU/hr)
B.10 ICS-50 – 1,725 lb/hr (1,674,000 BTU/hr)
B.11 ICS-60 – 2,070 lb/hr (2,009,000 BTU/hr)

Steam Output rating at 212 oF feedwater temperature, 0 psig (Sea Level to 2000 ft)

C. The boiler manufacturer shall have the capability to construct an engineered system, skid mounted,
including but not limited to mounting any number of boilers in a common system with common piping
headers and single source customer connections for single source steam supply, feedwater, drain,
electrical power, fuel supply, condensate return, and vents. Electrical panel boxes for the system must
be available along with all wiring requirements. Other available components shall include feed-water
tanks and pumps, chemical feed systems, water softeners, carbon filters, and various relevant valves
and other accessories. The system manufacturer shall have the engineering capabilities for all aspects
of the mechanical and electrical design aspects of the skid mounted system.
D. Customers, engineers and contractors shall have the option to visit the boiler manufacturer’s factory
to witness manufacturing, testing, and other operational safety inspections associated with the
referenced boilers.

2.2: BOILER CONSTRUCTION

A. The boiler shall be completely factory assembled as a self-contained unit. Each boiler shall be neatly
finished, thoroughly tested, and properly packaged for shipping.
B. The pressure vessel design and construction shall be in accordance with Section I of the ASME Code for
steam boilers. The boiler shall comply with CSD-1 code requirements and carry a UL listing (CAS/CUL
approval for Canada).

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 C. It shall be acceptable to vent the boiler using sealed combustion (drawing in fresh air from the
outdoors) or to draw air from the mechanical room itself.

C.1 The flue (exhaust) stack and any components associated with the stack must be
suitable for 1,000 F.
C.2 The stack arrangement must supply a negative .02” to negative .04” W.C. pressure with
the burner off.

D. The pressure vessel shell, furnace, and heads shall be SA-53B ERW/SA106B pipe or SA-516 Grade 70
plate and have the following thickness (150 psig design):
ICS Model Shell (Inches) Head (Inches) Furnace (Inches)
4 .375 .500 .365
6 .375 .500 .365
9.5 (100psi) .375 .500 .322
8.5/10 .354 .500 .365
15 .315 .500 .365
20 .313 .500 .500
25 .313 .500 .500
30 .313 .625 .500
50 .313 .625 .500
60 .313 .625 .500

E. The pressure vessel shall be insulated with compatible high temperature castable mixtures. The
pressure vessel subject to direct flame shall be insulated with high strength, low permanent linear
change, and high temperature limit castable. The remaining area shall be insulated with a lightweight,
low thermal conductive castable. These castables assure strength so that cyclic thermal stress and
cracking which can damage the insulation, does not occur. Insulation thickness shall be as follows:
E.1 4-15 BHP – 3 ½”
E.2 20 BHP – 4”
E.3 30 BHP – 4 ¼”
E.4 50-60 BHP – 4 ½”

F. The jacket shall be a minimum 20 gauge stainless steel.

2.3: BOILER DESIGN

A. The boiler shall be a vertical tubeless design with a centrally located furnace. The top mounted forced
draft burner will fire from the top of the boiler down through a circular furnace. The burner location
and firing method shall be such that combustion takes place within the water-backed furnace of the
boiler.

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B. The boiler input shall not exceed the fuel usage specified on the Fulton ICS Product Data Submittal for
the specified model size.
C. The capacity of each unit shall be able to produce continuously the steam rate specified by the steam
output on the Fulton ICS Product Data Submittal for the specified model size.
D. Adequate hand-holes shall be provided for access to the water side of the boiler. Hand-holes and
cleanout openings shall be provided at the lower part of the boiler so that the entire bottom of the
boiler may be cleaned.
E. The boiler will make use of welded convection fins to enhance heat transfer and distribute the flow of
flue gases.
F. The boiler shall have an optional configuration for dual fuel with natural gas/propane.
G. The boiler shall have an optional configuration for dual fuel with NG/LP and #2 oil. (Not available on
the ICS-4, ICS-6, or the ICS-25).
H. The boiler shall have an optional configuration for firing #2 oil only. (#2 oil option not available on the
ICS-4, ICS-6, or the ICS-25).
I. When firing with #2 oil, the boiler shall be provided with an oil pump assembly and all interconnecting
piping and components (valves, etc) to the burner.
J. The boiler shall have an optional configuration for NEMA 3R construction (outdoor operation).
K. The boiler shall have an optional configuration for digester gases and bio gases. Factory engineers
must have the opportunity to review and approve these applications in advance. Digester gases and
bio gases are not tested at the factory.
L. The water volume of the boiler shall not be less than:

L.1 ICS-4 – 14 Gallons (53 liters)

L.2 ICS-6 – 16 Gallons (60 liters)
L.3 ICS-8.5 – 24 Gallons (90 liters)
L.4 ICS-9.5 – 16 Gallons (60 liters)
L.5 ICS-10 – 24 Gallons (90 liters)
L.6 ICS-15 – 39 Gallons (147 liters)
L.7 ICS-20 – 77 Gallons (291 liters)
L.8 ICS-25 –82 Gallons (310 liters)
L.9 ICS-30 – 170 Gallons (643 liters)
L.10 ICS-50 – 245 Gallons (927 liters)
L.11 ICS-60 – 270 Gallons (1,022 liters)

M. The dimensions of the boiler in operation shall not be less than (Overall Width with water column x
Boiler Height with Trim and Fuel Train Assembly):

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 M.1 ICS-4 – 35.5 in x 63.5 in (902 mm x 1613 mm)
M.2 ICS-6 – 35.5 in x 73.5 in (902 mm x 1867 mm)
M.3 ICS-8.5 – 37 in x 80 in (940 mm x 2032 mm)
M.4 ICS-9.5 – 35.5 in x 83 in (902 mm x 2109 mm)
M.5 ICS-10 – 37 in x 80 in (940 mm x 2032 mm)
M.6 ICS-15 – 39 in x 86 in (991 mm x 2185 mm)
M.7 ICS-20 – 46.5 in x 91.5 in (1182 mm x 2375 mm)
M.8 ICS-25 – 47 in x 93.5 in (1194 mm x 237 mm)
M.9 ICS-30 – 52.5 in x 101 in (1334 mm x 2375 mm)
M.10 ICS-50 – 60 in x 106.5 in (1524 mm x 2706 mm)
M.11 ICS-60 – 60 in x 118.5 in (1524 mm x 3010 mm)

N. The approximate operating weight of the boiler shall not be less than:

N.1 ICS-4 – 1,617 lb (733 kg)

N.2 ICS-6 – 1,913 lb (868 kg)
N.3 ICS-8.5 – 2,200 lb (998 kg)
N.4 ICS-9.5 – 2,183 lb (990 kg)
N.5 ICS-10 – 2,200 lb (998 kg)
N.6 ICS-15 – 2,725 lb (1,236 kg)
N.7 ICS-20 – 4,392 lb (1,992 kg)
N.8 ICS-25 – 4,374 lb (1,984 kg)
N.9 ICS-30 – 6,868 lb (3,115 kg)
N.10 ICS-50 – 9,903 lb (4,492 kg)
N.11 ICS-60 – 10,512 lb (4,768 kg)

2.4: CONTROLS

A. The flame safeguard control shall be capable of either on/off or modulated type control and shall
provide the following:

A.1 The control shall provide a 30 second minimum pre-purge and post-purge time.
A.2 The control shall maintain a running history of operating hours, number of cycles, and
the most recent six control lockouts.

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 B. A flame observation port shall be provided.

C. The boiler shall be set up for 2:1 turndown for ICS 10-30 models and a maximum 3:1 turndown for ICS
50-60 models when firing on natural gas with modulated controls. The boiler shall be set up for 2:1
turndown for ICS 30-60 models when firing on #2 oil with modulated controls.
D. For modulated units, airflow shall be controlled by an airgate. Fuel flow shall be controlled by a
butterfly valve for gas operation. Both to be connected via linkage to modulation motor.
E. Burner selection and Burner and Safety Controls:

E.1 Burner location and firing method to be such that combustion takes place within the
water backed furnace of the boiler. Burner to be top mounted and of the down fired design.
Burner controls shall be of on/off or modulated as described above and are to include the
following:

i. Operating pressure control for automatic start and stop of burner operation.
ii. High Limit Pressure Controller with manual reset.
iii. Two low water cut-off probes to cause shut down of unit when water level drops to
minimum safe level (one in the water column and one in the boiler shell). The probe in the
shell shall be manual reset to comply with ANSI/ASME CSD-1 Code.
iv. Gas fired boilers shall have an air safety switch to prevent operation until sufficient
combustion is assured.
v. Flame detector to prove combustion.
vi. A contact for a feedwater pump shall be included and consist of a single phase motor starter
or optional contacts for a 3 phase pump.
vii. An electronic type combustion flame safeguard shall be included to provide full protection
against flame failure. The control shall maintain a running history of operating hours, number
of cycles, and the most recent six flame failures. This control shall have the capability to be
connected to a key board display module which will retrieve that information.
viii. 3-phase burner motor control shall have thermal overload protection.
ix. Burner motors shall be provided with fuse type overcurrent protection.

E.2 All controls to be panel mounted in a NEMA __ enclosure and so located on the boiler
as to provide ease of servicing the burner and boiler without disturbing the controls. Panel shall
be located to prevent possible damage by water, fuel or heat, of combustion gases. Controls
connected to water or fuel shall be installed outside the main boiler control panel. All controls
shall be mounted and wired according to Underwriters’ Laboratories requirements.

2.5: MAIN FUEL TRAIN COMPONENTS

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 A. A factory mounted main gas train shall be supplied. The gas train shall be fully assembled, wired, and
installed on the boiler and shall comply with CSD-1 and/or CSA code. Compliance with other codes is
available upon request. The maximum pressure rating of the components shall not be less than ___.

B. Standard CSD-1 fuel trains shall comply with IRI, which has been replaced by GE GAP. Normally open
vent valves are no longer required between the safety shut off valves. NFPA 85 compliance shall be
available from the factory to comply with local codes or regulations that specifically require a vent
valve.
C. Custom fuel trains are available upon request.

2.6: BOILER FITTINGS & TRIM

A. The boiler shall be supplied with an ASME Section I safety relief valve. The safety relief valve size shall
be in accordance with ASME code requirements and set at 150 psig for Section I Pressure Vessels
(100psi for the ICS-9.5). Custom set pressures upon request.
B. A water column shall be piped to the boiler at the factory. A gauge glass and drain valve will be
supplied. The gauge glass shall be protected by four brass rods. The water column shall also include
the primary low water cutoff prove to automatically shutoff burner operation when water falls below a
predetermined level. An auxiliary low water cutoff probe shall be mounted in the boiler shell. The
water column shall contain two water level probes, one to “start” and one to “stop” the feed water
pump.
C. A steam pressure gauge shall be included with the boiler, mounted on the water column, and shall be
complete with test connection.
D. Feedwater stop and check valve shall be supplied at factory in line to an internally baffled feed
connection in boiler shell to prevent thermal shock.
E. Additional standard trim shall include Y-type blow down valve and water column blow down valve.
F. A surface blowdown connection shall be provided, and provided with a manual valve.
G. A high water connection shall be provided as standard.
H. The boiler shall come with lifting eyes accessible for rigging. Transporting by fork lift is also acceptable.
I. Instructions for installation, operation and maintenance of the boiler shall be contained in a manual
provided with each boiler.
J. A wiring diagram corresponding to the boiler configuration shall be included with each boiler.
K. A factory test fire report corresponding to the boiler configuration shall be included with each boiler.

SECTION 3: Execution

3.1: INSTALLATION

A. Equipment and materials shall be installed in an approved manner and in accordance with the boiler
manufacturers’ installation requirements.

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 B. The installer shall construct a flat, level foundation designed to support the entire load. Calculations
shall be based upon the maximum or filled weight of the system. The boiler should be located in dry
surroundings on a level base, making sure that there is sufficient room around the boiler to enable the
operator and/or the maintenance engineer to gain access to all parts of the boiler. Check location for
ease of water supply and electrical connections. Place the boiler on a non combustible floor with
clearances to unprotected combustible materials, including plaster or combustible supports.
C. Assemble unit sections and parts shipped loose or unassembled for shipment purposes. Follow
manufacturer's installation recommendations and instructions.
D. Install electrical control items furnished by manufacturer per wiring diagram provided by
manufacturer.
E. Complete feedwater, steam, blowdown, fuel, safety valve discharge, and vent piping installation as
required by manufacturer for operation of system.
F. Provide applicable air intake and exhaust piping, size and type as recommended by the manufacturer
to maintain appropriate draft, and rated for the temperatures as listed above.

3.2: FIELD QUALITY CONTROL

A. After boiler installation is completed, the manufacturer shall provide the services of a field
representative for starting the unit and training the operator.
B. Arrange with National Board of Boiler and Pressure Vessel Inspectors for inspection of boilers and
piping. Obtain certification for completed boiler units, deliver to Owner, and obtain receipt.

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